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Mercury Mercruiser Sterndrive 1964 - 2006 Service Repair Manual Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Mercury. Read and print pages, or copy the entire manual to your hard drive. 1770 Pages MODEL YEAR: 1964 - 2006 MANUAL COVERS: SECTION 1 – 1964-1991 Type 1, MR Alpha and Bravo I and II – Carb and Fuel Injected Page: 2-600 SECTION 2 – 1992-2000 Gasoline Engines Alpha, Bravo, Blackhawk and All Inboard Transmissions Page: 602-1186 SECTION 3 – 2001-2006 Gasoline Engines and Drives Including Inboards and Transmissions Page: 1188-1770 MANUAL COVERS: 1 SAFETY INTRODUCTION CLEANING, WAXING, AND POLISHING CONTROLLING CORROSION PROPELLERS FUEL SYSTEM LOADING FLOTATION EMERGENCY EQUIPMENT COMPASS STEERING ANCHORS MISCELLANEOUS EQUIPMENT NAVIGATION 2 TUNING INTRODUCTION TUNING FOR PERFORMANCE MECHANICAL TASKS IGNITION FUEL SYSTEM Adjusting Idle Speed and Mixture 3 ENGINE INTRODUCTION/CHPT. COVERAGE GENERAL PRINCIPLES Piston Strokes & Combustion Valve Timing Engine Types TROUBLESHOOTING Cranking System Ignition System Compression Test Mechanical Problems Excessive Oil Consumption ENGINE REMOVAL, INSTALLATION AND ALIGNMENT PAN INSTALLATION -- All Models INTAKE MANIFOLD SERVICE EXHAUST MANIFOLD SERVICE CYLINDER HEAD SERVICE Removal Head Disassembling Cleaning & Inspecting Valve Mechanism Service Valve Guide Valve Seats Valves Valve Springs Hydraulic Lifters Head Assembling Head Installation PISTON, RING, & ROD SERVICE Removal Cleaning & Inspecting Assembling CYLINDER BLOCK SERVICE Piston & Rod Installation VALVE LASH ADJUSTMENTS Mercury Marine Engines GMC 4- & 6-Cyl. In-Line GMC V6 & V 8 Ford V 8 Only TIMING CHAIN, GEAR AND CAMSHAFT GMC 4- & 6-Cyl. In-Line GMC V6 & V8 Early Mercury Marine Mercury Marine & Ford CAMSHAFT BEARING SERVICE ALL UNITS Lift Measurement GMC Only Lift Measurement Mercury OIL PUMP SERVICE -- All Models Marine & Ford 3 ENGINE (CONTINUED) CRANKSHAFT ROD & MAIN BRGS. GMC 4- & 6-Cyl. In-Line GMC V6 & V8 Mercury Marine & Ford Crankshaft Installation 4 FUEL INTRODUCTION/CHPT. COVERAGE TROUBLESHOOTING Excessive Fuel Consumption Engine Surge Rough Engine Idle FUEL PUMPS AND FILTERS Single-Diaphragm Pump Dual-Diaphragm Pump Pump Pressure Test Pump Volume Test Fuel Line Test Fuel Pump Removal/Installation Fuel Filter Replacement Flame Arrestor Cleaning Water Separating Filter MODERN FUELS Sour Fuel CARBURETORS, GENERAL INFO. ROCHESTER BC Removal/Disassembling Assembling Adjusting CARTER RBS Description & Operation Disassembling Assembling Bench Adjus tments Synchronizing Dual Carbs. ROCHESTER 2GC & MerCarb Disassembling Assembling Bench Adjustmen ts ROCHESTER 4MV AND 4MC Description Disassembling Assembling Bench Adjus trnents HOLLEY CARBURETORS TWO-BARREL - 2300C FOUR-BARREL - 4150, 4160 & 4011 Description 6:Opera tion Disassembling - 2300C, 4150 & 4160 Cleaning 8 Inspecting Assembling Tuning Adjustments Disassembling - 401 1 Cleaning & Inspecting Assembling Tuning Adjustmnets EFI (ELECTRONIC FUEL INJECTION) Description & Operation Manifold Pressure ECU (Electronic Control) Fuel Pump & Routing Air Temperature Sensor Auxiliary Air Valve Manifold Absolute Pressure (MAP) Sensor Coolant Temperature Sensor Throttle Position Sensor Fuel Injectors Fuel Rail Fuel Pressure Regulator Oil Pressure Sensor Throttle Shutter Electric High Pressure Fuel Pump Water Separating Filter RPM Sensor Electronic Control (ECU) Troubleshooting EFI Installed Injector Test Voltage t o Elec. Pump Test Testing Fuel Pump Pressure Testing Injec tor Harness Testing Fuel Injectors Air Temp. Sensor Check Coolant Temp. Sensor Test Throttle Position Sensor Test EFI Maintenance Leaded Gasoline & Gasohol SERVICING EFI Removal Cleaning & Inspecting Installation Special Timing Words 5 IGNITION DESCRIPTION Standard Ignition System Ballast Resistor Shift Cutout Switch Ignition Timing Thunderbolt IV System TROUBLESHOOTING Compression General Tests Condenser Test Secondary Circuit Test Ignition Voltage Tests Spark Plug Troubleshooting Spark Plug Evaluation Polarity Check DISTRIBUTOR SERVICE Removal SERVICING A DELCO-REMY Disassembling - from a 4- o r 6- cylinder engine Assembling Disassembling from a GMC V8 Assembling SERVICING A MALLORY Disassembling from a V8 engine Assembling SERVICING A MERCURY MARINE Disassembling from a V8 Assembling SERVICING AN AUTOLITE OR PRESTOLITE Disassembling from a V8 Assembling ADJUSTING POINT GAP ALL DISTRIBUTORS 5-27 DISTRIBUTOR INSTALLATION MCM 185 229 CID All Other Engines Adjusting Dwell Adjusting Timing DDIS (DIGITAL DISTRIBUTORLESS IGNITION SYSTEM) 6 ELECTRICAL INTRODUCTION BATTERIES JUMPER CABLES DUAL BATTERY INSTALLATION GAUGES AND HORNS Oil and Temperature Gauges Warning Lights Fuel Gauges Troubleshooting Tachometer Horns CHARGING SYSTEM Alternator Troubleshooting Servicing Charging System with Separate Regulator Servicing Delcotron Alternator Servicing Valeo Alternator Troubleshooting Removal Cleaning & Testing Brushes Testing Alterna-tor Assembling & Installation CRANKING SYSTEM Troubleshooting Delco-Remy Cranking Motor Description & Operation Servicing Testing Assembling Autoli-te Cranking Motor Description & Operation Disassembling Bench Tests Assembling Prestolite Cranking Motor Description & Operation Disassembling Assembling 7 REMOTE CONTROLS INTRODUCTION SHIFT/STEERING CABLE EARLY TYPE SHIFT CABLE SERVICE -- PRIOR T O 1973 7 REMOTE CONTROLS (CONTINUED) EARLY TYPE SHIFT (Continued) Attaching Shift Cable Mounted on Starboard Side Adjusting Shift Cable Mounted on Starboard Side Attaching Shift Cable Mounted on Port Side Adjusting Shift Cable Mounted on Port Side LATE TYPE SHIFT CABLE SERVICE 1973 TO 1982 Installation Dimensions Shift Cable Installation Shift Cable Adjustment SHIFT CABLES SINCE 1983 MODELS R, MR, AND ALPHA Upper Shift Cable Installa tion Lower Shift Cable Installation BRAVO SHIFT CABLE SERVICE Shift Cable Adjustment Stern Drive Removed Shift Cable Adjustment Stern Drive Installed Cut-Out Switch -- Lever Position Adjustment Reverse Lock Valve Adjustment COMMANDER CONTROL SHIFT BOX Removal/Disassembling Cleaning & Inspecting Assembling STEERING SYSTEMS DIRECTIONAL INDICATOR SYS. Disassembling Cleaning & Inspecting Assembling ROTARY STEERING SERVICE Disassembling Cleaning & Inspecting Assembling POWER STEERING DESCRIPTION & OPERATION SYSTEM MAINTENANCE Adding Hydraulic Fluid Bleeding System Belt Adjustment Actuator Valve Adjustment POWER STEERING COOLER INTRODUCTION MECHANICAL TILT MECHANISM HYDRAULIC SYSTEM System Operation UP Circuit UP and DOWN Circuit Trailer ingllaunching GENERAL SERVICE INSTRUCTIONS TROUBLESHOOTING Mechanical Problems Electrical Problems TESTING SYSTEM COMPONENTS PURGING AIR (BLEEDING) SYS. Early Model Systems -- Both Hoses Connected t o Fwd. End of Cylinder L a t e Model Systems -- One Hose connected to Each End of Cylinder TRIM SENDER SYSTEMS Disassembling Assembling L4djustrnents REVERSE LOCK VALVE Description Disassembling Assembling Adjustment PUMP MOTOR Troubleshooting Disassembling Cleaning & Testing 9 COOLING DESCRIPTION TROUBLESHOOTING SERVICE DRAINING 6 In-Line Engines w/Std. Sys. In-Line Engines w/Closed Sys. V8 Engines w/Std. Sys. V8 Engines w/Closed Sys. WATER PUMP THERMOSTAT HEAT EXCHANGER In-Line Engines V8 Engines FILLING SYSTEM EXHAUST MANIFOLD GMC In-Line Engines 470 Engine Ford V8 Engines GMC V8 Engines EXHAUST SHUTTER STERN DRIVE WATER PUMP Lower Unit Removal Pump Installation Lower Unit Installation BRAVO WATER PUMP ON ENGINE Disassembling Cleaning & Inspecting Assembling STERN DRIVE NOTE PAGES 10-2 THRU 10-58 COVER ALL UNITS, EXCEPT BRAVO PAGES 10-58 THRU 10-110 COVER BRAVO STERN DRIVE INTRODUCTION OPERATION TROUBLESHOOTING SERVICE PRECAUTIONS PROPELLER REMOVAL TRIM CYLINDER REMOVAL STERN DRIVE REMOVAL UPPER GEAR HOUSING Disassembling Cleaning & Inspecting U-Joint, Drive Gear and Bearing Disassembling Assembling Upper Gear Housing Assemb. Upper Driveshaf t and Driven Gear Assembling Adjustments Bearing Preload Adjust. Driven Gear Shimming U-Joint Bearing & Bearing Assembly Installation Drive Gear Shimming LOWER UNIT Housing Removal Disassembling Cleaning & Inspecting Reverse Bearing Carrier Propeller Shaft Lower Unit Assembling Forward Gear Backlash Reverse Gear Backlash Pinion Gear Shimming Forward & Reverse Gear Shimming Water Pump Installation Lower Unit Installation UPPER GEAR HOIJSING T O LOWER UNIT ASSEMBLING STERN DRIVE INSTALLATION TRIM CYLINDER INSTALLATION PROPELLER INSTALLATION STERN DRIVE LUBRICATION BRAVO STERN DRIVE INTRODUCTION OPERATION TROUBLESHOOTING BRAVO SERVICE Propeller Removal Braining Lubricant Separating Stern Drive From Bell 1-Iousing Separating Upper Gear C a s e Housing From Lower Unit Upper Gear C a s e Service Rear & Top Cover Removal Bearing Removal U-Joint Shaft Removal Clutch Disassembling Shif ter Bushings & Seal Cleaning & Inspecting Assembling Bearing & Sleeve Instl. Shif ter Bushing & Seal Clutch Assembly U-Joint Shaft Assembly Spacer & Rolling Torque Lower Unit Service Disassembling Bearing Carrier and Propeller Shaft Driveshaf t Propeller S h a f t Bearing Cleaning & Inspecting Assembling Lower Unit Driveshaft Bearing Carrier Drive Gear & Bearing Driveshaf t Bearing Races Drive Gear & rives shaft 10 STERN DRIVE (CONTINUED) BRAVO LOWER UNIT Continued) Shimming 10-102 Pinion Gear Height Driveshaft Preload Backlash & Rolling Torque Mating Lower Unit To Upper Gear C a s e Housing Mating Stern Drive t o Bell Housing Propeller Installation Stern Drive Lubrication 11 BELL HOUSING INTRODUCTION TROUBLESHOOTING GIMBAL HOUSING & TRANSOM PLATE INSTALLATION CONNECTING HYDRAULIC HOSES In-Line Engines V8 Engines 13 ENGINE REMOVAL/INSTALLATION INTRODUCTION REMOVAL INSTALLATION In-Line Engine Throttle Cable Installation and Adjustment V8 Engine Throttle Cable Installation and Adjustment SERVICE PROCEDURES 14 MAINTENANCE GIMBAL HOUSING BALL BEARING Removal Installation TRANSOM SHIFT CABLE Removal Installat ion EXHAUST BELLOWS Removal Installation U-JOINT BELLOWS Removal Installation BELL HOUSING Removal Disassembling GIMBAL RING Removal Disassembling Cleaning & Inspecting Assembling 2 Installation BELL HOUSING Assembling & Installation 12 GIMBAL HOUSING INTRODUCTION TRANSOM PLATE Removal Cleaning & Inspecting INTRODUCTION ENGINE SERIAL NUMBERS STERN DRIVE IDENTIFICATION AND SERIAL NUMBERS SHIFT IDENTIFICATION ALL UNITS, EXCEPT BRAVO BELOW WATERLINE SERVICE ENGINE FLUIDS OFF-SEASON STORAGE STE RN DRIVE LUBRICATION Filling/Draining Models 1, IA, 18, 1 C All Others, Incl. Bravo PRE-SEASON PREPARATION APPENDIX CONVERSIONS Metric Drill Size TORQUE VALUES TUNE-UP SPECIFICATIONS CARBURETOR SPECIFICATIONS ENGINE SPECIFICATIONS MCM888/225S/223/250/260/320 l5O/l6O/l65 6-Cyl. In-Line APPENDIX (CONTINUED) ENGINE SPECIFICATION (Continued) MCM11011201120MR 4-Cyl. MCM140 6-Cyl. In-Line MCM140/140MR 4-Cyi. UPPER DRIVESHAFT GEAR RATIO LOWER UNIT BACKLASH WIRE IDENTIFICATION AND ROUTING Instrument Cluster with Warning Light Thunderbolt Ignition Instruinen t Panel Model 120, 140, 165 (Check Serial Numbers) Model 898 Model 888, 225-S, 233 (Check Serial Numbers) Model 470 & 485 w/air-cooled vol tage regulator Model 470 & 485 w/water-cooled voltage regulator Model 120R/140R MCM 120R/140R & 3.0 Litre without fuse MCM 120R/140R & 3.0 Litre with fuse MCM 4701488 MCM 470R/488R w/o fuse MCM 470R/488R with fuse MCM 898R/228R/260R/230 also 5.0 & 5.7 Litre MCM 200 and 898R with fuse MCM 165/170MR/180/190MR MCM 185/185R V6 MCM 20 5 V6 MCM 230/228R/260R, also 5.0 & 5.7 Litre with fuse MCM 320 with EFI MCM 330 Sc 7.4 Litre w/o fuse MCM 330 & 7.4 Litre with fuse DDIS (DIGITAL DISTRIBUTORLESS IGNITION SYSTEM Power Trim circuit wldouble solenoid Power Trim qircuit w/one solenoid Power Trim w/late push button w/two solenoids A-62 Prestolite Power Trim Oil Dyne Series IV Since 1983 Com mander side mount controls w/power trim/tilt Language: English Format: PDF COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS (WINDOWS 10, WINDOWS 8, WINDOWS 7, VISTA 32 and 64, XP, ME, 98, NT, 2000 ETC.) Windows/Mac/Tablet/Phone Friendly 32 / 64 bit